Asynchronous rejection in an inserter

ABSTRACT

A material processing system for collating and feeding documents as collations for insertion into an envelope, comprising first and second feeding modules, and an insertion module, each of the feeding modules including document position sensing means and a controller, each of the feeding module controllers responsive to a first signal for creating a collation of documents and generating a second signal indicative of the collation, the second signal indicating an error condition in the collation when the sensors indicate non compliance with the first signal, means for passing the second signal from each feeding module controller to the insertion module, a rejection station positioned in the insertion module, the insertion module including a base controller, the base controller connected to the feeding module controllers and responsive to a collation error condition in the second signal for activating the reject station and rejecting the collation.

RELATED APPLICATIONS

The following related applications refer to subject matter related tothe subject matter of this application:

U.S. application Ser. No. 279,000, filed Dec. 2, 1988, now U.S. Pat. No.4,928,807

U.S. application Ser. No. 242,566, filed Sept. 12, 1988, now U.S. Pat.No. 4,852,334

U.S. application Ser. No. 281,607, filed Dec. 9, 1988

U.S. application Ser. No. 292,613, filed Dec. 30, 1988

U.S. application Ser. No. 292,156, filed Dec. 30, 1988

U.S. application Ser. No. 292,060, filed Dec. 30, 1988

U.S. application Ser. No. 292,616, filed Dec. 30, 1988

U.S. application Ser. No. 292,059, filed Dec. 30, 1988

U.S. application Ser. No. 292,150, filed Dec. 30, 1988

U.S. application Ser. No. 292,058, filed Dec. 30, 1988.

FIELD OF INVENTION

This invention relates to document collating and envelope stuffingmachines, and in particular to an automatic machine of the foregoingtype capable of higher speeds and increased reliability and flexibility.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 4,169,341 describes an automatic document collating andenvelope stuffing machine comprising a main flow path employing acontinuous conveying mechanism to an envelope stuffing station, in whichone or more feeding stations deposit documents onto a platformassociated with each feeding station. The documents in each platform arepicked up seriatim by the conveying mechanism and subsequently stuffedinto envelopes. The feeding stations are each in parallel with the mainconveying mechanism, which operates continuously to pick up whateverdocuments are present on each feeder platform.

While this machine operates satisfactorily for its intended purpose, itdoes have certain inadequacies which limit its flexibility and speed.For example, the speed is determined solely by the main conveyingmechanism, which proceeds at the same velocity even though documents arenot present on the platforms. Moreover, it is difficult to keep track ofthe collation contents from station to station. Still further, it isdifficult, if not impossible, to employ a single address document withcoding to indicate the collation contents which can control each of thefeeding stations in turn.

Particularly, it is difficult to establish a communication protocolbetween modules in a modular insertion system which will permit maximumspeed of operation while not restricting the manner in which modulesinter-communicate. This is an important aspect for features such asqueuing, pass collations, rejecting erroneous collations, passing errormessages recognizing and adding new modules without the requirements ofchanging switches or re-programming memory, and multi-languagecapability for nonEnglish language countries.

DESCRIPTION OF THE PRIOR ART

The patents to Tomlinson et al U.S. Pat. No. 4,564,901 and Ward U.S.Pat. No. 4,636,947 each relate to parallel processing systems utilizingconcurrent data transfer, the former specifically directed toasynchronously intercoupled microprocessors.

Prodel et al (U.S. Pat. No. 4,646,245) and Ropelato (U.S. Pat. No.4,771,374) relate to modular manufacturing and process controls;Stiffler et al (U.S. Pat. Nos. 4,608,631 and 4,484,273) teach modularcomputer systems per se: Crabtree et al (U.S. Pat. No. 4,604,690)provides for dynamic reconfiguring of a data processing system for addeddevices; and Shah et al (U.S. Pat. No. 4,589,063) and Vincent et al(U.S. Pat. No. 4,562,535) disclose automatic configuration in singlecomputer systems.

The patent to Davis et al (U.S. Pat. No. 4,354,229) shows a loopintialization process.

The patent to Innes (U.S. Pat. Nos. 4,615,002 and 4,595,908) relates tothe multilingual features.

SUMMARY OF INVENTION

An object of the invention is a document collating and envelope stuffingmachine that can operate at high speeds.

A further object of the invention is a document collating and envelopestuffing machine that provides complete control of the collationcontents.

Another object of the invention is a document collating and envelopestuffing machine that is more flexible in its operation, by which ismeant that the machine can control the contents of each collation byprogramming each feeder station, or by providing an address documentcoded with the collation contents which controls each feeder, or by anoperator manually instructing each feeder station of the documents it isto contribute to the collation.

These and other objects and advantages as will appear hereinafter areachieved with a novel document collating and envelope stuffing apparatuscharacterized by a plurality of local feeding stations with each locatedin series in the main document flow path. Each local feeding station isprovided with a local queuing station directly in the main flow path.Each feeding station, in turn, captures the global collation created bythe previous upstream feeding stations, adds if desired one or moredocuments to the collation, and then passes on to the next downstreamstation the resultant global collation. A computer record is kept of theglobal collation and as documents are added the computer record isupdated and passed on to the next feeding station. The basic system maybe called on-demand feeding. Each local feeding station in turn notifiesthe next local feeding station when its collation is complete so thatthe next feeding station is prepared to accept and contribute its owndocuments if desired to the global collation. The last feeding station,on demand, then feeds the resultant global collation to the envelopestuffing station which can be followed if desired by a flap moisteningand sealing station and ultimately by a sorter or postage machine ifdesired. In accordance with another feature of the invention, theaccumulated collation record is checked for completeness, and ifincomplete, the stuffed envelope is ejected from the main flow path.

This invention is also directed to a material processing system forcollating and feeding documents as collations for insertion into anenvelope, comprising first and second feeding modules, and an insertionmodule, each of the feeding modules including document position sensingmeans and a controller, each of the feeding module controllersresponsive to a first signal for creating a collation of documents andgenerating a second signal indicative of the collation, the secondsignal indicating an error condition in the collation when the sensorsindicate non compliance with the first signal, means for passing thesecond signal from each feeding module controller to the insertionmodule, a rejection station positioned in the insertion module, theinsertion module including a base controller, the base controllerconnected to the feeding module controllers and responsive to acollation error condition in the second signal for activating the rejectstation and rejecting the collation.

Principal benefits derivable from the machine of the invention include:

(1) the ability to add on additional feeding stations as modules withoutchanging the basic operation. These additional feeding stations caninclude sheet feeders, bursters, which separate individual sheets fromperforated fan-folded continuous paper, folders and like documenthandling apparatus;

(2) the speed of the machine is not fixed, but is instead dependentprimarily on the time required for each local contribution to thecollation. Thus if no local contribution is made, no unnecessary delaysare encountered at that feeding station;

(3) the collation record which is passed on from station to station iskept up to date and provides a reliable record of the collation contentsat every station in the machine.

(4) the up-to-date collation record can readily be used to controlsubsequent machine operations, such as ejection in case of a defectivecollation;

(5) if an address document is used, it retains its position on top ofthe collation stack and thus can be readily scanned to control themachine, and, when the global collation is stuffed in the envelope, theaddress on the address document can be readily positioned to be visiblethrough a window in the envelope.

The system employs asynchronous operation with no reciprocating motion.Previous inserter systems have operated asynchronously, but they haveused a ram type reciprocating operation for insertion. This organizationand structure reduces the vibration and noise and allows a lightermachine to be constructed. The queuing station arrangement and queuingdevice accumulates and holds documents in collation order until a downstream module calls for the collation to be transferred. If a jam isencountered in one station, jam clearing becomes much quicker because itis not necessary to disturb other collations in different module queuingstations, as all the other queue stations are in the wait state. Theuser only has to clear one station. A two belt system is employed forpositive drive of collation through the insertion station. Positive highspeed control is obtained by a continuous belt insertion drivemechanism. The continuous belt insertion provides a new form ofinsertion not previously used. Prior art devices use a large wheel witha small roller which has to be operated synchronously. The use of thesame device for both conveying a collation and also inserting it into anenvelope is unique. After insertion, the envelope is turned 90 degreesand sent to the next module for moistening and postage application. Thedevice also provides for asynchronously operating the envelope turner inrelation to the inserter operation. The asynchronous relationshipbetween the envelope turner and the inserter allows the inserter toreject erroneous collations without having to operate the turner andother downstream equipment. The electronic control of the presentinvention uses a unique communication arrangement which combinescommand/response and peer to peer communications. When the system is onbut not running in insert mode, the communication is a command/response,master/slave communication arrangement. This is a one-to-onecommand/response protocol where the master, the base envelope feedermicroprocessor, retains command and control over the various insertermodule microprocessors. However, while the system is running in insertmode, the communication technique changes to a peer to peer or module tomodule transfer mode wherein each module creates a record of itsactivity, known as a piece record, and passes it onto the next module.Master/slave communication is precluded during this mode of operation.Normal communications between modules during insert mode (not during,for example, a jam requiring user intervention) are transparent to theuser. This allows the use of a single UART for dual purposecommunications. It allows the throughput of large volumes of informationbecause the processing is in parallel in each module and the datatransfer throughout the modules is concurrent.

The system also allows for automatic configuration of equipment on powerup, and generates (each time it powers up) the necessary operatingconfiguration information of the equipment. Prior systems require aconfiguration PROM installed in the PROM had to be generated andphysically changed. It should be noted that such equipment allowed theuser to select features within the configuration, but not to change theconfiguration itself.

The ring of topology of the present invention facilitates geographicaddressing for module identification. The system employs a mastercontroller operating in conjunction with the module computer. The systemconfiguration analysis command from the master controller during thepower up sequence requires each module in the inserter to send databack. Because of this arrangement, the base system will have storedtherein the number of modules and their respective addresses. The baseneed not know the particular nature of the modules. This allows for theaddition of new and as yet unknown modules to the system. The softwarearchitecture is such that all messaging is displayed on the base module(all inserter configurations have an envelope module). Because allmessages that are displayed are generated by the various insertermodules and transmitted to the base module microprocessor for display ona display screen (in any language the operator selects) the system isflexible and allows the addition of new modules that do not presentlyexist. This permits module additions without having to change any of theexisting software. Modules such as bar code readers, OCR readers,scanners, sorting devices, etc., can be easily added.

Error messages can also be passed from module to base unit directlywithout passing through other modules along the second channelcommunication link. Error messages are pre-stored in each module. Theprestoring of error messages also allows the automatic selection offoreign language error messages.

The electronics in each module allow for generation of a piece record insoftware regarding each collation. A piece record is generated by theelectronics and is passed from module to module, without passing througha master controller, asynchronously through the inserter, from onemicroprocessor to another. The piece record corresponds to the physicalcollation which is being moved from module to module. It represents animage of the physical collation. Because of this architecture, one canpass a large amount of data in block format from module to module.Modular prior art systems typically worked in a master slaverelationship and the concept of direct module to module or peer to peercommunication in this context is unique. The piece record is a dynamicdata structure and accommodates different sizes of collations indifferent runs. The piece record is passed in a sequenced arrangement,module to module, but not necessarily passed between the modulessynchronously with the physical movement of the documents. Since, thepiece record is dynamic, it can include data for running a printerand/or any currently unknown or new I/O device.

A preferred embodiment of the invention will now be described in greaterdetail with reference to the accompanying drawings, wherein:

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one form of apparatus in accordance withthe invention;

FIG. 2 is a schematic side of the apparatus of FIG. 1 showing the maindocument transfer devices and sensors;

FIGS. 3a-3d illustrate schematically the asynchronous operation of theapparatus of FIG. 1;

FIGS. 4a and b an illustration of the reject mechanism of FIG. 2.

FIG. 5 is a block diagram of the interrelating electronics system foroperating the apparatus of FIG. 1;

FIG. 6 is a block diagram of the electronics of a single module.

FIG. 7 is a block diagram of the electronics of the base unit.

FIG. 8 is a block diagram of the microprocessor employed within a singlemodule.

FIG. 9 is a block diagram of the microprocessor employed within a baseunit.

FIG. 10 is a flow chart illustrating the program routine and system flowwithin the base unit.

FIGS. 11A and 11B are flow charts illustrating the program routine andsystem flow within a module.

FIG. 12 is a continuation of the program routine within the base unit.

FIG. 13 is a supplemental flow routine.

FIG. 14 is a flow chart illustrating the messaging subroutine.

FIG. 15 is a memory map illustrating the translation routine.

FIG. 16 is a program routine and system flow chart illustrating thetranslation routine.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 of the drawings show a perspective view on a table 5 of themachine 10 of the invention provided with two document feeding stations12, feeding station keyboard for data entry 12a, a transport station 13,electronics control station 14, with associated message display screen15 and data key board 16, an envelope feeding station 17, an envelopestuffing station 18, a turning and ejection station 19, a moistener andsealing station 20, and a stacking station 21. Although only twodocument feeding stations are shown, it will be appreciated that manymore feeding stations can be added on to the front end of the machine,which has been indicated by the dashed lines 22 shown at the left end,and the operation of the overall machine does not change. Such feedingstations or modules include bursting and folding modules also. Theability to add additional modules without the necessity of reconfiguringboth mechanisms and the central electronics is an important feature ofthe novel machine of the invention. The keyboard 16 is used to provideoperator input as to start, operating instructions, reset functions andthe like. The display 15 is employed to show error messages, modulestatus, echo keyboard instructions and the like.

The following detailed description will be more understandable with thebrief description of the underlying concepts and operation of themachine now outlined. Each feeding station is independent of otherfeeding stations and its operation is controlled by a localmicroprocessor. Each feeding station, of which one or more may beincluded in the machine is typically provided with a hopper for storinga stack of documents, and a plurality of sensors connected to its localmicroprocessor for controlling the feeding of one or more of itsdocuments to the global collation, and signalling the receipt anddeparture of the global collation. Each feeding station contains aqueuing station for temporarily capturing and holding the globalcollation.

When the queuing station of the current feeding station is empty, itslocal microprocessor is signaled and deposits into its local queuingstation the one or more documents it is instructed to contribute. Thisinstruction may come manually from an operator through the keyboardlocated on the side of the feeder, be programmed into the localmicroprocessor through the base unit keyboard, or be derived from acoded address document, typically the top document of the collation,which has been read by a scanner at an upstream feeding station and theinformation passed on to the local feeding station. When the localcontribution is completed, the upstream microprocessor is signaled tosend down the so-far accumulated global collation, which is accomplishedby opening a gate at the previous queuing station and activating afeeder mechanism which then deposits the global collation on top of thelocal contribution at the current queuing station. This process, it willbe noted, ensures that an address document, previously on top of thecollation, remains on top at the current queuing station. Each localmicroprocessor is passed in turn a collation record, which records thedocuments contributed to the global collation, and each microprocessorin turn updates the collation record and passes it downstream to thenext feeding station, or, if the last, to the envelope stuffing station.When the global collation is completed at the current feeding station,the next downstream feeding station or envelope stuffing station isinformed. The global collation remains at the current queuing stationuntil the next downstream station is ready to receive the globalcollation. This is the basis for the on-demand feeding label, which isessentially an asynchronous operation in which local stations controlthe collation feeding while within the local domain, i.e., its localqueuing station. There is also a main computer or microprocessor whichcan communicate with each of the stations in the machine, but thecollation record is transferred directly from local microprocessor tolocal microprocessor, instead of via the main computer. The operation ofthe envelope stuffing machine is similarly locally controlled by thestate of the immediately upstream feeding station, except that anydefects in the collation records passed on to it will result in ejectionof that stuffed enveloped from the main flow path.

The schematic side view of FIG. 2 provides crosssectional detail of themodules of FIG. 1. Each feeding station 12 comprises a hopper forstacking a supply of documents designated 50 at the first station and 51at the second station. The operation of both feeders 12 is the same,hence the description given below for the second feeder applies equallyto the first. Transport means shown as rollers 34 feed one or moredocuments from the stack 51 down an inclined deck 23 onto a transportmeans shown as a belt drive 24. The belt drive is preferably twoparallel belts, 24A and 24B (not shown), which provide positive highspeed drive control on each side of the documents. At the right end ofthe belt drive 24 is a queuing station 25, represented by a gate 26which blocks advance of documents and a solenoid 27 for lifting the gate26 to allow documents to advance to the next downstream station. Thequeuing station also includes a pressure roller 33. The queuing stationoperation is a two-step process, involving rotary motion of the stationarm 35 about the pivot point 36. The document transport is via the beltdrive 24 which is blocked by the gate 26. When the downstream module isready to receive the document or documents resident at the queuingstation, the solenoid 27 is activated, causing rotation of arm 35 aboutthe pivot 36, and causing the gate 26 to rise out of its positionblocking movement of the documents and placing pressure roller 33 down,forcing the document against the belt 24, resulting in transport of thedocument by the belt 24 to the next module. The rollers 34 are activatedby a motor (not shown) and the transport 24 by a motor 28. Since a dualbelt drive is used, the queuing station is duplicated on both sides ofthe document, once for each belt. This arrangement is duplicated inevery module queuing station.

A plurality of sensors are present, such as, for example, opticalsensors that can detect the presence or passage of a document. Thesensors in FIG. 2 are shown as units spaced across the document path,typically a light emitter and a photo-detector operating in atransmission mode (well known in the art) for clarity, but combinedemitter-detectors operating in a reflective mode (also well known in theart) are preferred. Typically, each place where documents stand or passis provided with a sensor to keep track of the document flow. Thus, eachhopper has an input sensor 29 to determine the presence of stackeddocuments, and an output sensor 30 for detecting the leading andtrailing edge of passing documents to know how many have passed andwhen. Similarly, the queuing stations 25 each have an input sensor 31 toknow when documents arrive, and an output sensor 32 to know when theyhave left. This sensor arrangement is repeated in each module in thesystem.

The envelope stuffer 18 has been described in detail in copendingapplication, Ser. No. 242,566, filed on Sept. 12, 1988, assigned to theassignee of the present invention and incorporated herein by reference,and need not be repeated. For present purposes, only the flow isnecessary. The envelopes 41, stacked on a hopper 42 with the usual input43 and output 44 sensors, are fed by roller transport means 45 down aninclined deck 46 through transport means 47 where each envelope isstopped at queuing station 48 comprising a gate 49 and gate-openingsolenoid 37. Sensor 38 is the input sensor for queuing station. When theenvelope is stopped at the gate, finger grabbers 52 are activated toopen the envelope, with the result that documents into the openenvelope. The sensor 55 senses proper loading into the envelope.Assuming proper loading, and readiness o±the downstream module 19, thegate 49 is open, and the associated pressure roller 56 applies pressureto the envelope against the transport belt 57, causing the envelope totransport to the next module 19

The stuffed envelope passes to the turner station module 19, the turnermodule being described in detail in copending application, Ser. No.279,000, filed Dec. 2, 1988, assigned to the assignee of the presentinvention and incorporated by reference herein. The envelope istransported by transport belt 61, driven by roller 62, under pressure ofpivotable pressure roller 63, whereupon it comes to rest against a stop64. Reject mechanism 65 (not shown), if a reject condition exists, willeject the document in a direction transverse to the document path.Absent a reject condition, the envelope is rotated 90°, from a positionwherein the opening of the envelope is transverse to the feed path, to aposition where the opening of the envelope is parallel to the feed path,as described in the aforesaid application, Ser. No. 279,000. Next thefeed path is raised relative to the document stop 64, as shown in FIG.2, so that the envelope is free to move, the pressure roller 63 drivingsame against the belt 61, through pressure roller 66, to the nextstation 20.

It will be evident that a principal advantage of the invention is theability to be able to reject an unopened or damaged envelope, allowingmultiple attempts at inserting any given collation that is being held inqueue.

Because the inserter is an in-line system, an appropriate location toreject the envelope is out of the turn station 19, 90° to the directionof the mailpath, in to a tray 19A (FIG. 1) that would be in closeproximity to the operator for manual handling, area and positionedagainst the stops 64 in the turner 19 before the turning cycle isstarted. This is an appropriate reject point because the envelope is notconfined on both sides by transporting or turner mechanisms and it isstationary. The reject mechanism 65, accomplishes the reject function.

Referring to FIG. 4, the rejection device is made up of a soft,constantly turning roller 81 on a long swinging arm 82 whose homeposition is out of the mailpath 83. Positioned under this roller is acurved ramp 84 that can move up and down by the action of a solenoid 85.The curve of the deck is such that when the arm swings through itstravel, the ramp will always be below the turning roller. One end ofthis curved deck is under the lower left corner of the smallest envelope84 that the machine will handle. When it is desired to reject anenvelope the solenoid 85 activates lifting the deck until it hits itsstop 87 which is adjusted such that the turning roller 81 engages thedeck 84 providing the power to swing the arm 82 in the direction of theenvelope 88 which is up against the turner reject position 86 and thearm 82 will hit its stop 90. At this time the turning roller grips theenvelope 88 and sends it out of the machine 91 into the tray 19A. Atthis time the solenoid 85 is turned off and the deck 84 drops downallowing the arm 82 to return to its home position 92 driven by thetorque of the vertical shaft 93 and the return spring 94. A sensor 95(not shown) is positioned in an appropriate location to sense thesuccess or failure of a reject operation. Failure can include a rejectreport operation, which repeats all of the foregoing steps. Failure mayinclude, for example, a dual feed into the turner station, wherein thereject operation removes only the uppermost of the dual feed documents,thus requiring a repeat reject.

Referring again to FIG. 2, in station 20 the stuffed enveloped passesthrough a flap moistener represented as a wetted wick and reservoir 67,disclosed in greater detail in aforesaid copending application Ser. No.281,607 a flap sealer represented by rollers 68, and then transported bythe drive postage meter. The usual condition detection input 20A andoutput 20B sensors for the moistener are present.

The machine operation will be clearer from FIGS. 3a-c, which showdocument positions during successive time periods. For clarity, therightmost queuing station will be designated 25A, the previous upstreamqueuing station 25B, and the leftmost queuing station 25C. FIG. 3aassumes a stack of documents 70, previously referred to as the globalcollation, which is at a rest position at a queuing station 25C of theupstream feeder 22, with an address document 71 on top (shown smallerfor clarity). A controller meanwhile has instructed the next module 12to feed one document 51 from its hopper to be added to the globalcollation. So, while the collation 70 waits at its queuing station, oneset of the documents 51 is deposited in the local queuing station 25B,shown at FIG. 3b. The sensors having informed the controller thatdocument 51 is present in station 25B, then the controller opens thegate 72 at station 25C and the global collation moves downstream to thenext queuing station 25B where it is halted by the gate 26B. Thedownstream path, indicated by the curved deck 73, is such as to depositthe global collation 70,71 on top of the document 51. This is shown inFIG. 3c. Meanwhile, station 25C having been emptied, can now be filledwith the upstream global collation 74, shown with its address document75 on top. FIG. 3c also shows that the downstream feeder 12 hasdeposited a document 50 from its hopper onto its queuing station 25A.

The last view shows another snapshot of the system at a subsequent time.The global collation 51, 60, 71 at station 25B has moved downstream toqueuing station 25A and placed on top of document 50. Upstream, adocument 51 has been deposited at station 25B, and the system is readyto advance global collation 74, 75 downstream to station 25B.

An important feature is that each local station operates asynchronously,that is, substantially independently of the other stations feeding wheninstructed local documents to its local queuing station, and calling forthe upstream global collation to be passed on to it as soon as its localfeeding is over. Hence, local deposit of documents at multiple feedersis not synchronized, each feeder doing its own local feeding undercontrol of a local controller. Similarly, global collation movementsdownstream are not synchronized but are passed on, on demand of andunder control of the next downstream controller. Input and outputsensors are employed at each module where appropriate The sensors areconstantly sending messages to the local controllers informing them ofdocument arrivals and departures. Each local controller possesses theability to transmit information to a central controller. Similarly, thetransport and feed mechanisms are similarly activated as needed and inan asynchronous manner. Although not shown, multiple sensors may beemployed along each belt at each station to ensure bilateral symmetry ofmovement (absence of skew) along the mail path.

The operation of the envelope stuffing, turning moistening and sealerstations is similar. The envelope stuffer will not call for the globalcollation at 25A until an envelope is positioned, opened and ready forstuffing. Similarly, no stuffed envelopes will feed downstream until theturner moistener and sealer are ready to receive it. Additional moduleoperations such as bursters, scanners, postage meters sorters andstackers, whether upstream or downstream may be employed in this system,with similar sensor arrangements, local controllers and queuing.

A schematic of a system block diagram in accordance with the inventionis given in FIG. 5.

The overall communication concept employed herein is the concept ofcommand/response, a unique communication arrangement. When the system isnot running the communication is a command/respond, master/slavecommunication arrangement. This is a one-to-one command responseprotocol where the master controller, here the base envelope feedermicroprocessor, retains command and control over the various insertermodule microprocessors. The overall communication concept employedherein is a unique communication arrangement of combiningcommand/response and peer to peer communications. Peer to peercommunication is also termed piece record transfer changes to a piecerecord transfer mode. Master slave communication is precluded duringthis mode of operation. If there is a need to communicate betweenmodules (not a jam requiring user intervention) such communication istransparent to the user. This allows the use of a single UART for dualpurpose communications and allows the throughput of large volumes ofinformation because the processing is in parallel in each module and thedata transfer throughout the modules are concurrent.

The system also provides for automatic configuration of equipment onpower up, and generates (each time it powers up) the necessary operatingconfiguration information of the equipment. The ring of topology of thepresent invention facilitates a geographic addressing mode. The systemconfiguration analysis command initiated by the master controller duringthe power up sequence requires each module in the inserter to identifyitself, serially, by tagging an address onto the command initiated bythe base control unit and to pass the tagged data back to the mastercontroller. Because of this arrangement, the system knows the number ofmodules and each module address. It does not, however, have to know theparticular nature of the modules, i.e. feeder, burster, etc. This allowsfor the addition of new and yet unknown modules to the system.

In the running mode, a serial topology is employed. Thus, theelectronics in each module allow for generation of a piece record insoftware regarding each collation. A piece record is generated by theelectronics and is passed from module to module asynchronously along theserial data link from one module microprocessor to the next. The piecerecord corresponds to a physical collation of the document set which isbeing moved from module to module. It represents an image of thephysical collation. Because of this architecture, one can pass arelatively large amount of data in block format from module to module.The piece record is a dynamic data structure and accommodates differentsize in different runs. The piece record data is in a sequencedarrangement and is passed between the modules in accordance with thecommunication protocol, and not necessarily synchronously with thephysical movement of the documents. The piece record can include datafor running a printer and/or any currently unknown or new I/O device.Also, communication continues between modules on a local level,including local handshake factors for release of queued documents.

The software architecture is such that all messaging is displayed on thebase or envelope module (all inserter configurations have an envelopemodule). Because all messages that are displayed on the base aregenerated by the various inserter modules and transmitted to the basemodule microprocessor for display on the display (in any language theoperator selects) the system is flexible and allows the addition of newmodules that do not presently exist. This permits module additionswithout having to change any of the existing software. Modules such asbursters bar code readers, OCR readers, scanners, sorting devices,postage meters, printers etc., can be easily added, both upstream ordownstream from the master controller.

The communication system of the present invention will now be set forthwith greater detail in connection with FIG. 5. As shown in FIG. 5, theelectronics controlling the base unit, that is to say all portions ofthe inserter shown in FIG. 1 with the exception of the add-on modulesdesignated generally as 12, is designated as block 100. The electronicsfor each individual module 12, designated as modules 1, 2 and 3 forpurposes of illustration, correspond to elements 102, 104 and 106 itwould be understood that additional modules may be added, the dash linessuch additional module insertion The electronic interconnection betweenthe base unit control 100 and the module is set forth on a dual basis.First, local handshake signals are provided from base unit control 100along the local handshake data line 108 to module 102, along bus 110 tomodule 102, bus 112 to module 106 and bus 110 to additional modules andultimately to the base unit controller. The function of the localhandshake signal data bus is to interconnect specific interunitcommunication signals in accordance with the operation of the device.Thus, the lines are shown as bi-directional, with the capability ofexchanging information as required between the respectivemicroprocessors contained within each of the units, 100, 102, 104 and106. The base unit control 100 is further connected along data line 116for point to point unidirectional serial data flow to the module 102.The module 102 is coupled to the module 104 along the unidirectionalserial bus 118 module 104 coupled to module 106 along the unidirectionalserial data bus 120, and the module 106 coupled to the base unit control100, through any intermediate module in the same manner, alongunidirectional data bus 122. A second level of communication is providedbetween the base unit control 100 and each of the respective modulesalong the multi drop global serial-parallel data bus 124. This data busis also bi-directional and serves the function of a direct means ofcommunication between each of the modules and the base unit control.Thus, two levels of data communication are illustrated, first providingfor serial information exchange from the base unit control through eachof the respective modules, and a second level of communication providingfor direct communication between the base unit control 100 and each ofthe respective modules 102, 104, and 106. The purpose of dual levelcommunications is to maximize the speed of information exchange and thusto maximize

Referring now to FIG. 6, a generalized diagram of each individual moduleillustrating the relative relationship between respective components insuch modules is shown. As indicated therein, the basic electronics foreach individual module is contained within a module control board 130which has respective input port 132 and output port 134 to input devices136 and output devices 138. Input devices will include the variousdocument position sensors indicated hereinabove with respect to theexplanation of the FIGS. 1 and 2, as well as local switch settings andthe like. The output devices will include various solenoids and relays,and display devices, and also as illustrated hereinabove. In additionthe control board will drive respective power sources, including themotor drive indicated generally as 138, driven by DC motor control 140under the control of an AC interlock control unit 142. The motor 138corresponds to motor drive 28 shown schematically in FIG. 2.Informational input to each individual module may be provided by meansof a scanner and scanner control module 144 which may consist of aconventional optical scanner or the like, suitable for inputtinginformation from a document, such as the document 71 illustrated inconjunction with the explanation set forth in FIGS. 3A-D or other inputmeans derived for the purposes of inputting feeding information withrespect to a document stack contained by the respective module.

As shown in FIG. 5, each of the various modules has means for passinginformation relative to preceding modules there through. Thus, as shownin the module electronics schematic of FIG. 6, bi-directional moduleinterface signals corresponding to lines 110, 112, 114 of FIG. 5 areprovided into a terminal block 146 along pluralities of data line 148.The point to point unidirectional serial data bus 116 illustrated inFIG. 5 is shown generally along the data lines 150. Outputs from themodule are provided through the upper terminal 152, and include theserial links between each of the modules, the serial link to the firstmodule from the base unit, the multi drop command line port coupled tothe multi drop global serial-parallel data bus 124, illustrated in FIG.5, and other bi-directional module interface signals required for handshaking mode and the like.

Referring to FIG. 7, a more detailed illustration of the functionalrelationship of the elements contained within the base unit control 100is illustrated As illustrated in FIG. 7, the base unit controlelectronics includes a computerized base unit control board 160containing a plurality of input and output data lines, coupled throughport 162 These data lines include the serial link from the upstreammodule the serial link to the first module in the system, thebi-directional module interface signals, the system status bus and themulti drop command lines, among others The base unit control electronics160 further includes input port 164 and output port 168. The input port164 is coupled to a series of input devices 166, which include theplurality of sensors positioned throughout the various areas of the baseunit module, as shown in FIG. 2. The output terminal port 168 is coupledto a plurality of output devices 170, which may include inter-activemechanical components such as the turning station and reject stationnoted in conjunction with FIGS. 2 and 4. In addition, the control board60 is also coupled to AC and interlock control 172 which is in turncoupled to a filter 176 for receiving the AC power from input 176, andprovides filtered AC to the AC output terminal 178 for powering themodules. The AC and interlock control 172 is also coupled to the motorcontrol circuit 180 which in turn supplied regulated DC current to theDC motor 182 which is employed for driving the transport mechanisms andbelt drivers illustrated in conjunction with the explanation set forthabove in FIG. 2. Input and output ports 164 and 168 are also coupled tothe motor control circuitry for communicating signals relative to thecontrol of this motor The operator interface module 184 i s coupled tooutput of the electronic control board 160 for providing a interfacebetween the keyboard 16 and display screen 15 in the electronics controlstation 14, illustrated in conjunction with FIG. 1.

In reference to FIG. 8, a detailed description of the computer controlof the base unit control board 160 is illustrated. The data link isprovided through input data port 190, and through timer 192 to themicroprocessor 194 which is typically of the intel 8051 family ofmicroprocessors. A port expander 196, which may be an Intel type 82C55receives output signals from the microprocessor 194 and places theseoutput signals into various data lines for inter connection to therespective remote modules. The decoder section 198 responds to signalsreceived from the microprocessor 194 for interfacing with the timer 192,and the keyboard and display unit illustrated generally as unit 200. Themicroprocessor 194 operates in conjunction with random access memory 202for temporary data storage and a permanent read only memory 204 forsupplying the program control in the microprocessor 194.

Referring now to FIG. 9, a more detailed diagram of the module controlboard 130 of FIG. 6 is illustrated. Each individual module is controlledby a local controller, such as the microprocessor 220, which ispreferably of the Intel 8051 family, coupled to a local data transferbus 222 receiving local intermodule handshake signals through the localmodule handshake interface buffer 224 Local data transfer bus 222 alsoreceives signals from the local input section 226 which includes thedocument position sensors illustrated in conjunction with theexplanation set forth in FIG. 2, local keyboard input, and other inputdevices. The data transfer bus also provides output signals from themicroprocessor 220 to the local output section 228 for controllingelectromechanical components contained within the module such as motionclutches for driving the transports, solenoids for disabling the drivemotors and activating the queuing stations, and relays for activatingstatus lights and other power functions. As set forth above inconjunction with the explanation of the operation of FIG. 2, the datatransfer bus 222 also carries signals to the buffer 230 for the globalmulti drop interface bus 124 (FIG. 5). Block 232 includes EPROM forprogram storage for local program control and RAM for temporary storageare also coupled to the microprocessor local data transport bus 222 in aconventional manner. Microprocessor 220 also receives the signalsderived from the point to point serial interface bus through buffer 234.

With reference now to the block diagram of FIG. 10, the softwareroutines utilized to establish operation of the electronic controlsystem of the inserter of the present invention will be described.

The system provides for automatic configuration of equipment on powerup, and generates (each time it powers up) the necessary operatingconfiguration information of the equipment. Prior art systems require aconfiguration PROM installed in the PROM had to be generated andphysically changed. It should be noted that such equipment allowed theuser to selected features within the configuration, but not to changethe configuration itself.

The system employs a master controller operating in conjunction with themodule computer. The ring of topology of the present inventionfacilitates geographic addressing for module identification. The systemconfiguration analysis command promulgated by the base unitmicro-processor during the power up sequence requires each module in theinserter to send data back. Because of this arrangement, the base unitmicroprocessor will have stored therein the number of modules and theaddress of each. It does not, however, need to know the particularnature of the modules. This allows for the addition of new and yetunknown modules to the system. The software architecture is such thatall messaging is displayed on the base module (all inserterconfigurations have an envelope module). Because all messages that aredisplayed on the base are generated by the various inserter modules andtransmitted to the base module microprocessor for display on a displayscreen (in any language the operator selects) the system is flexible andallows the addition of new modules that do not presently exist. Thispermits module additions without having to change any of the existingsoftware Modules such as bar code readers, OCR readers, scanners,sorting devices, etc., can be easily added.

Referring again to FIG. 5, the present invention accomplishes thispurpose by utilization of the uni-directional serial data busline 116,in which the base unit addresses all modules serially using a globalsystem command sent on the serial channel Geographically speaking, thecontrol signal is sent to the furthest module first The base unitmaintains a table of addresses of each of the modules in the system.Thus, conceptually the base unit initiates a control signal by a commandwhich is sent to module 1, and module 1 applies as a tag to the command,signal a local address indicating its presence and, if desired itsconfiguration. The tagged command signal passes along the serial databus 118 to module 2, wherein module 2 adds its address and configurationto the data and so on through module 3 and the remaining modules untilit returns to the base control unit wherein it is stored in memory.

Referring now to FIG. 10, the program routine for the base moduleprovides first for the initiation of the startup routine from the baseunit control, in block 300. The next step in block 310 is theperformance of local diagnostics within the base control unit Next,block 312, a module address assignment is initiated by passage of ageographic address command along the serial data bus. The modulesrespond, as described above, by placing an address and, if desired, typedesignation code or tag on the command signal, and passing same onto thenext module, and so on, until the signal returns to the base unitwherein it is stored in memory. Thereafter, in block 314, the systembranches in accordance with the optional selections made by the operatorregarding the modes in which the inserter may operate. These modesinclude START, SINGLE CYCLE, SET UP TO CHANGE PARAMETER MODE or REPORTMODE. Options are displayed on the local screen, and the operatorchooses by keyboard inputting a choice. The remaining options in block314 are SINGLE CYCLE, SET UP TO CHANGE PARAMETERS and REPORT MODE. InSINGLE CYCLE, the program runs through only one insert operation andstops. In SET UP TO CHANGE PARAMETERS the communication protocol createsa window into each module once the base unit becomes a terminal whichallows the operator to communicate directly with each module. The REPORTand DIAGNOSTIC (a separate mode not accessible from the screen) modesoperate similarly, i.e., by command/response communication. If theoperator chooses the start mode, the operation proceeds to block 316wherein the first stage of the operation is to shut down theinterchannel communication represented in FIG. 5 by communicationbetween blocks 102 and 104, 104 and 106, etc. The program next entersblock 318 and begins the run mode. In the run mode, the base unit sendsout a global command on the serial channel that tells each individualmodules to enter a run mode, in response to which each module preparesfor a document transfer to process paper. Once entering the run mode,the base unit awaits the receipt through each module along the serialchannel of the signal indicating each module has effected run modetransfer operation. This occurs in block 320. Upon receipt by the baseunit control of a confirmation signal through each of the successivemodules, the signal is examined, block 322, to determine whether or notthere are any problem checks, that is to say, whether any problems haveoccurred in each of the individual modules. Since each module has aunique channel address, a problem occurring in each of any individualmodules will manifest itself by the module's own identification addressin the base unit control system. As indicated in decision block 324, anyproblems that are determined to have occurred will cause the system flowto proceed to block 326, where it is then determined which module has aparticular problem. Through the message capability of the base unit,problems that occur in any individual module are specifically identifiedand displayed to the operator, block 328, in the base unit controlelectronics display 15, see FIG. 1. In block 330, operator input isawaited for purposes of correcting any specific problem which may havebeen displayed upon the display screen as a result of the analysis ofblock 322. Upon confirmation of the operator of correction of theproblem, the cycle begins again as indicated by the legend "1" in acircle, corresponding with the circled 1 in the start block of 314, andrepeats itself Assuming the absence of a problem in the first orsuccessive cycles, decision block 324 indicting same in the NOdirection, then directs the flow to enter the run mode step 332. Afterentering run mode, the system transfers its operation, block 334, from acommand-response, master-slave communication arrangement, which is aone-to-one command protocol where the master unit retains command andcontrol over the various inserter module microprocessors, to a piecerecord transfer mode. The electronics in each module allow forgeneration of a piece, also termed collation record, in softwareregarding each collation. A piece record is generated by the electronicsand is passed from module to module, without passing through a mastercontroller, asynchronously through the inserter, from one microprocessor to another. The piece record corresponds to the physicalcollation which is being moved from module to module. It represents animage of the physical collation. Because of this Architecture, one canpass a large amount of data in block format from module to module. Thepiece record is a dynamic data structure and accommodates differentsizes of collations in different runs. The piece record is passed in asequenced arrangement, module to module, but not necessarily passedbetween the modules synchronously with the physical movement of thedocuments Since the piece record is dynamic, it can include data forrunning a printer and/or any currently unknown or new I/O device. Thebeginning of the collation record generation, block 336, results in allcommunications between modules being done in a manner which istransparent to the base unit control, along the serial data channelHandshaking communications take place along the communication links 110,112, 114, and piece record transfer along the links 11B, 120 and 122(FIG. 5). Errors requiring operator intervention are transmitted to thebase control unit by means of the multidrop global serial paralleldatabus 124, by which background mode communication is maintainedbetween the base unit control 100 and each of the respective modules.Thus, transfer of a large volume information is possible becauseprocessing is in parallel and each module and data transfer takes placein a concurrent manner.

Referring to FIGS. 11A & 11B, a module flow routine is shown. The piecerecord generate command block 336 begins the module flow routine. Thepiece record, also termed collation record, represents all of theparticular data associated with a particular run through an individualfeeding module. The first step in the generation of the collation recordis the activation of the motor drive in the first feed module, block338. In block 340, the module then scans for the control signal for datawhich is to control the operation of the individual feeder. This datamay include a number of specific documents for a run, the number ofindividual documents which may be included from that specific feeder,particular documents which will be required for an insert operation,and, in the case of downstream modules, information regarding thereceipt of specific information from upstream modules. This data may beprovided from a control document, read optically or by bar code, orinput on the module keyboard, may be transmitted from the base unitcontrol, or may be sent as part of a data link communication from aremote source. The three options are illustrated as side paths, block342.

it is also possible for multiple instructions to be issued in eachmodule. Thus, for example module 1 could contain a multipart invoicewith instructions on collation, module 2 could contain a checkcorresponding to the invoice with its own instruction In block 344, theoperation is commenced. Upon completion of the operation, a completerecord, termed a collation or piece record, block 346, formed in memoryin the microprocessor circuitry of the feed module is created. The piecerecord is handed off from module to module when the current module hascompleted its collation operation. However, release of the queuingstation and passing the collation onto the next module, will only occurwhen the down stream module signals it is ready to accept same. Thus,the piece record transfer is not necessarily synchronous with thecollation movement. In block 350, the piece record is handed off to thenext module, along the the point-to-point bidirectional serial data bus11B. At the same time, a ready signal, indicating that module 1 has itsdocuments in queue, ready to send, is passed, block 348, to module 2,the next downstream module. The next module processor M2 repeats thesame routine, FIG. 11B, as M1, with corresponding operation blocks shownwith the same reference numbers but with "A" suffixes. When M2 hascompleted its collation operation, and has its documents ready at itsqueuing station it acknowledges same, block 348A by providing its readysignal back along the bidirectional link to the first module processor.At this point, block 349, the first module processor M1 releases itsqueuing station and the first module collation passes to the secondmodule queuing station where it is combined with the second modulecollation. See FIG. 3a-d. Meanwhile, a similar operation has occurred atthe next downstream module, if any. It is noted that the piece record,that is the data status which defines the collation of the first module,has been forwarded to the next module when the collation has beenachieved at the first module, along the serial data link 118. Thisoperation is part of the handshaking mode. Thus, the piece record is notnecessarily synchronous with the actual passage of the physicalcollation from module to module. This multi-level communicationdecreases the processing time of the present invention.

Each module includes a switch on its key panel for enabling on line, offline and automatic. If, for example, the module is on line and theswitch is set for two there are then two documents in each cycle foreach piece. There are two reading operations in the module. First, theinstructions on the incoming document are checked to see if there areany specific instructions. If the module is off line, the incoming piecedocument, which provides the collation instruction to the module, isignored. If the module is on line, application are defined either by theinput document, by the local hardware where set up was done on the localkeyboard, or its input buffer if there was a set-up instruction passedthrough by the base unit.

In the change parameter mode, where the base unit acts as a terminal forthe local module, communication is set up along the serial data link.The module is addressed by the base unit, in accordance with the tagsignal placed thereon as explained in the start up mode. Hence, throughthe base unit keyboard, the local module can be programmed for anoperation, and those instructions stored in the input buffer.

The collation or piece record is incremented by the information added inmodule 2, and passed on to the next module. This operation continuesthrough each of the individual modules, shown by the dash line 352 and352A, until the collation record is received and placed into the baseunit block 354 (FIG. 12). It will be understood that program steps shownin FIGS. 11A and 11B are all program instructions taking place withineach individual module. Base unit flow chart, which ended at block 334,then resumes at block 354 when the collation record is received in thebase unit. At this time, block 356, the base unit causes the insertoperation to take place, as was described in conjunction with FIG. 2. Atthis point the base module checks the collation record in block 358 todetermine if any specific errors have been sensed at any stage or stepin the insertion process. The several error checking routines will bedescribed in further detail hereinafter, however each complete collationrecord provides an overall status for reject conditions. If thecollation records indicate that a good run has taken place, decisionblock 360 sends the program to the turning step in block 361, FIG. 12,then to sealing, in block 362, and ends the operation in block 364. Ifthe collation decision, block 360, indicates a bad collation record,caused for example by overweight insertions, then block 364, a rejectionstep takes place in block 366, energizing the ejection solenoid (FIG. 4)and the program sends the transmission of an appropriate error messagein block 368.

Referring to FIG. 13, a subroutine in each module monitors erroroperation. Thus, timing block 370, and paper moving block 372conditions, as examples, are continually monitored. Failure, Ncondition, forces a status check, block 374, wherein a Y indicates suchcondition is proper and the system recycles, block 376. An N conditioncauses a system pause, block 378, explained in further detail below.

Referring to FIG. 14, the error routines and messaging concept employedin conjunction with the present invention is illustrated. Thus, as shownherein, the first stage of the program in block 400 is a scan routine.The scan routine is continuous and operates throughout the entireoperation of every insertion run. During the scan routine, the base unitcontrol 100, along the multidrop global serial parallel databus 124,interrogates each of the respective modules 102, 104, 106 . . . The baseunit scans each respective module for conditions which will continuouslyreport machine status and does so along the multidrop global serialparallel interface bus 124, illustrated by an arrow line interconnectingeach of the modules to the base unit. Thus, the base unit scans forproblems, block 400, and a decision block 402 detects presence orabsence of error messages. In the absence of an error message, the scancycle simply continues again, indicated by the N, or No line emergingfrom the decision block 402. In the event a problem does occur, the baseunit enters a pause mode, and produces a pause mode signal at block 404,and an error message is generated. Messaging is handled so that eachmodule has the entire text of an error message contained within itselfEach time a module error is signalled, the base unit simply displays theerror message from each module upon receipt thereof, each module beingindividually identified as explained and above in conjunction with thestart up process by a unique address placed upon each module in theinitial scan routine. The initiating of an error message may be promptedby a series of specific error indications, such as out of paper, paperjam, improper movement of a document and the like, indicated in theexplanation of FIG. 2. The error line may be driven by any module, andconsists of a read-write line which the base unit samples at regularintervals. Each of the modules continually checks for a pause signal,block 406. In the event a pause signal is present, each module begins ashutdown, block 408, wherein a module operation in progress iscompleted. Module operation is frozen at the end of any specificoperation convenient for completion and data stored for later restart,block 410. Stated simply, the error line is driven by the modules andread by the base unit. The pause line is driven by the base unit andread by the modules. The pause mode allows each of the modules to finishup their operations, reaching a point where each individual module motormay be turned off and returned to a command-response mode, block 412. Atthis point, block 414, the module inserts a busy line into the multidropline indicating that each module has completed its operation to aconvenient point, and that individual modules are synchronized withrespect to an up or down stream module. Piece records at this stage arenot transferred, but the serial data link is now clear for the responsein command-response mode, block 416. Beginning at the base unit, astatus request command is issued, block 418, along the serial data bus116, received first by module 102, with a status request. If the statusrequest of module 102 returns negative, the signal is passed along bus118 to module 104 and a similar request made of module 104. Thisoperation is indicated in decision block 420, wherein a NO response of astatus request to module 102 will result in the next successive downstream module address added to the status request, block 422, and thecycle repeating in 418 requesting the issuance of a report, this time inthe next successive module. Should this module now respond with an errorresponse, block 424, an appropriate status report will be provided tothe base unit, along with the message to be displayed on screen. Asindicated above, each module contains the entire text of the message foreach of the respective errors which a module may wish to display in thebase unit display. Thus, the module responds with its address plus amessage, which is passed through along the serial data link 116 alongsuccessive modules to the base unit for display on the base unit displayscreen. This is indicated in block 426. At this point, operatorintervention is awaited, block 428. Additional message indicators may beprovided in each respective module, such as red and green display lightsindicating such errors as OUT OF PAPER, PAPER JAM and the like. If anOUT OF PAPER is displayed in the operator screen, the operator then isprovided with an indication to that effect, either in the form of avisual or audible alarm, and the entire operation of the machine isplaced in a suspended operation until the operator has reset themechanism to correct the error. At this point, piece records are stillawaiting transfer in their respective microprocessors in each of themodules, and the system is on suspension pending restart, indicated inblock 430. Once the error is corrected, the operator re-starts, and theoperation then resumes. Resumption of the operation resumes continuingsuccessive scans, block 432. The error scan operation then repeatsitself. Along with the resumption of the scan operation, a record iskept, block 434, of the errors occurring throughout the system. The baseunit keeps an accumulative count of errors per run, along with the typesof errors. The error may be stored at the moment of storage of block412, when the module has finished its preceding operation. This errorrecord is added to the piece record. The piece record is passed on theserial link from module to module, as explained above, until it reachesthe base unit. Thus, the base unit may keep track of errors by storing,from each piece record as it is received, the location and type oferror. Such data may be derived totally from the piece record after thebase unit receives same, and may include other additional informationwhich is stored as a result of piece record report requirements,including piece count, collation errors, jams, etc.

The piece record includes the length of the record, number of bytes,including control bytes, the control bytes containing bits indicatingwhether paper is present, the last piece tag, whether collation is inerror in batch processing, first piece, last piece, presence or absenceof the control document, functions for downstream modules, selectionsmade according to collation records or document numbers, and otheradditional information. The current preferred length of piece record is256 bytes for the purpose of conserving memory; however, it will beunderstood that the piece record may be varied in accordance withoperator needs.

There is a local handshaking operation between modules and betweenmodules and the base unit, noted in FIG. 5, and designated in buses 108,110, 112, 114 . . . etc. Local handshaking includes information such as,piece ready, piece record release, piece release, etc., all of which areutilized for specific control of transmission of upstream moduledocuments by release from the queuing station to the next successivedownstream module. Each of the respective sensors indicated in FIG. 2serve as part of the error indication for each module. The sensors areused to point out error flags to the local microprocessor and eachrespective module on a timing basis for indicating whether or notdocuments are in the proper location and the proper sequence. Any errorindicated by improper sensing of documents at the incorrect time resultsin the placement of an error flag in the local microprocessor, and theseerrors are picked up during system status checks periodically made alongthe multidrop global serial parallel data bus line, as described above.

The unique operation of permitting each individual module to haveentirely pre-stored error messages within each module allows formulti-language translation to be utilized in conjunction with thepresent invention. In this instance, each module is provided with anEPROM, containing an plurality of pre-stored messages, includingmessages such as OUT OF PAPER, PAPER JAM and other messages relating tothe feeding of multiple documents at each respective feed stations,translated into as many different languages as may be conceivablyemployed for units shipped anywhere in the world. Thus, the advantage ofencoding EPROM on this basis is that individual coding of error messageson a customized basis depending upon the specific language requirementof the user need not be done on a customer-by-customer basis. The systemis effected in the present invention by the use of a multi-languagetranslation selection, which is selected upon startup with eachrespective machine operation. The difficulty encountered with multiplelanguages is the difference in the number of letters for each message,and the present invention provides a unique method of indexing through avariable character set, in accordance with how many characters eachmessage contains. The system operates on a pointer basis. Thus,referring to FIG. 15, a memory map shows the arrangement wherein aplurality of messages, four by way of example are stored in an EPROM,each message taking up a specific, but necessarily different, amount ofpre-stored space, constituting pluralities of characters. It will beunderstood that additional languages may be feasible, and that manyerror messages may be present. Thus, the first message indicated asblock 501 may be in English, whereas the successive messagesconstituting the same message but in another language and occupying adifferent message length is shown at 502, 503 and 504 respectively.Thus, the error message shown on at 501 may be in English, 502 may be inFrench, 503 in German, and 504 in Spanish. The translation subroutinefor selecting appropriate message is illustrated in FIG. 16, and formspart of the subroutine of the startup operations. The first step of thesubroutine is to index the pointer 506 to the first message shown inblock 510, and referring to EPROM memory storage location area 501. Thesystem automatically defaults to English, which is indexed as the firstmessage, and then allows the operator to switch languages. The sensingof the switching of languages block 512, carries in decision block 514.The sending may result from a manually set switch or a keyboard enteredresponse to a screen displayed question. A NO response, indicating thatlanguages are not to be switched, allows the subroutine to return to themain program, block 516 Should there be a language switch, the pointer506 is reset depending upon the language selected The system employs amultiplier concept, meaning that if the second language is selected,block 502, a multiplier of 1 is provided. The third language, block 503,is a multiplier of 2, and the fourth language is a multiplier of 3. Thefirst character of each language indicates the number of characterspresent in that respective language, this block is indicated as firstcharacter byte 501A of block 501, 502A of block 502, 503A of block 503and 504A of block 504. The language switch step 512, FIG. 16, willindicate specific multipliers for the pointer 506 reset in block 518. Asthe pointer is reset, from block 501 to 502 if a number greater than 0is selected, the pointer will move to the first byte position 502A frombyte position 501A by the amount of characters indicated in the firstbyte position 501A and amounting to the number of characters stored inthe first message translation plus one. Thus, if there are 40 charactersin English, byte 501A will indicate 41 characters present in message501. The additional character represents the byte storing the characterinformation. If the pointer is to be reset, pointer 506 moves to thefirst byte portion of the language indicated by its multiplier, 1, 2, 3,which is an indication the number of times the reset operation is totake place. Thus, if language block 504 selected, the multiplier is 3,the software routine first analyzes character byte position 501A,determines the number of characters, and jumps to character position502A. This is only the first iteration. If 3 iterations have beenselected, the operation repeats itself a second time, moving to block503A, calculating the move by the number of character positions storedat the first pointer indexing position found in block 502A. Theoperation then repeats again, causing the translation pointer to pointto block 504A, which is the selected language. Thus, as shown in FIG.16, after the initial pointer reset, block 518, the character quantityis read, block 520, and the pointer jumps by the character quantity,block 522. At this point, if the number of jumps equals the languageselection multiplier, decision block 524, then the program routinereturns to the startup subroutine, block 516. If it does not, then thejump counter is incremented by 1, block 526, and program returns toblock 518 for a repeat of the operation. The operation continues torecycle until the jump(s) equals the selected multiplier language(s),thereby indicating the pointer now at the correct language translationerror message.

Without further analysis, the foregoing will so fully reveal the gist ofthe present invention that others can, by applying current knowledge,readily adapt it for various applications without omitting featuresthat, from the standpoint of prior art, fairly constitute essentialcharacteristics of the generic and specific aspects of this contributionto the art and, therefore, such adaptations should and are intended tobe comprehended within the meaning and range of equivalence of theappended claims.

What is claimed is:
 1. A material processing system for collating andfeeding documents as collations for insertion into an envelope,comprising first and second feeding modules, and an insertionmodule,each of said feeding modules including document position sensingmeans and a controller, each of said feeding module controllersresponsive to a first signal for creating a collation of documents andgenerating a second signal indicative of said collation, said secondsignal indicating an error condition in said collation when said sensorsindicate non compliance with said first signal, means for passing saidsecond signal from each feeding module controller to said insertionmodule, a rejection station positioned in said insertion module, saidinsertion module including a base controller, said base controllerconnected to said feeding module controllers and responsive to acollation error condition in said second signal for activating saidreject station and rejecting said collation.
 2. The material processingsystem of claim 1 wherein said rejection station comprises a solenoid, adeck movable by said solenoid, a roller movable by said deck, a swingingarm on which said roller is mounted and movable by said roller such thatit functions to sweep a rejected envelope out of said rejection stationthrough an opening dedicated to said rejected envelopes.
 3. The materialprocessing system of claim 1 further comprising a sensor connected tosaid rejection station and functioning to determine the success orfailure of a reject operation.
 4. The material processing system ofclaim 2 further comprising a sensor connected to said rejection stationand functioning to determine the successor failure of a rejectoperation.
 5. The material processing system of claim 3 furthercomprising means connected to said sensor for repeating said rejectoperation in the event that failure is indicated.
 6. The materialprocessing system of claim 4 further comprising means connected to saidsensor for repeating said reject operation in the event that failure isindicated.
 7. A method for collating and feeding documents as collationsfor insertion into an envelope, said method comprising the stepsof:sending a signal from a feed module controller to a base controllerin a base module in the event that a collection error exists, causingsaid base controller to respond to said error signal such that itactivates a reject station to reject said collation.
 8. The method ofclaim 7 further comprising the step of employing a sensor connected tosaid reject station and functioning to determine the success or failureof reject operation.
 9. The method of claim 7 wherein said rejectstation functions to reject said collation by activating a solenoidwhich impinges upon a deck, said deck then impinging on a roller mountedon a swinging arm such that said swinging arm sweeps a rejected envelopeout of said base module through an opening dedicated to rejectedenvelopes.
 10. The method of claim 8 further comprising the step ofinitiating a repeat of said reject operation in the event of a failureindication.
 11. The method of claim 9 further comprising the step ofemploying a sensor connected to said reject station and functioning todetermine the success or failure of a reject operation.
 12. The methodof claim 11 further comprising the step of having initiating a repeat ofsaid reject operation in the event of a failure indication.
 13. Aninsertion module for a system for collating and feeding documents ascollations for insertion into an envelope, said insertion modulecomprising:a reject station and a base controller, said base controllerresponsive to a signal indicative of a collation error condition foractivating said reject station and rejecting said collation.
 14. Theinsertion module of claim 13 wherein said reject station comprises asolenoid, a deck movable by said solenoid, a roller movable by saiddeck, a swinging arm on which said roller is mounted and movable by saidroller such that it functions to sweep a rejected envelope out of saidinsertion module through an opening dedicated to said rejectedenvelopes.
 15. The insertion module of claim 13 further comprising asensor connected to said reject station and functioning to determine thesuccess or failure of a reject operation.
 16. The insertion module ofclaim 6 further comprising means connected to said sensor for repeatingsaid reject operation in the event that failure is indicated.
 17. Theinsertion module of claim 14 further comprising a sensor connected tosaid reject station and functioning to determine the success or failureof a reject operation.
 18. The insertion module of claim 17 furthercomprising means connected to said sensor for repeating said rejectoperation in the event that failure is indicated.
 19. An inserter systemfor collating and feeding documents as collation for insertion into anenvelope, comprising:a feeding module including a controller, a baseunit controller, operatively connected to said feeding modulecontroller, a rejection station, operatively connected to said base unitcontroller, said feeding module controller being responsive to a firstsignal for creating a collation of documents and generating a secondsignal indicative of said collation, said second signal indicating anerror condition in said collation when an error is detected inprocessing of said collation, means for passing said second signal fromsaid feeding module controller to said base unit controller, said baseunit controller being responsive to said second signal for activatingsaid rejection station and rejecting said collation when said secondsignal indicates said error condition in said collation.
 20. Theinserter system according to claim 19 further comprising additionalfeeding modules, each of said additional feeding modules including acontroller, each of said additional feeding module controllers beingresponsive to said first signal and generating an update to said secondsignal indicative of processing said collation in any of said additionalfeeding modules.
 21. The inserter system according to claim 20 furthercomprising means for passing said second signal from said feeding modulecontroller to said additional feeding modules controllers and from saidadditional feeding modules controllers to said base unit controller. 22.The inserter system according to claim 21 wherein said rejection stationcomprises a solenoid, a deck movable by said solenoid, a roller movablyby said deck, swinging arm on which said roller is mounted and movablyby said roller such that it functions to sweep a rejected envelope outof said rejection station through an opening dedicated to said rejectedenvelope.
 23. The inserter system according to claim 22 furthercomprising a sensor connected to said rejection station and functioningto determine success or failure of a reject operation.
 24. The insertersystem according to claim 23 further comprising means connected to saidsensor for repeating said reject operation in the event that failure isdetermined.